Haulotte Group xlb-4725a, Operator'S Maintenance Manual

Page 1: ...OPERATOR S MAINTENANCE MANUAL B33 01 0104 Rev 4 August 2012...

Page 2: ...ome countries require that operators are licensed to operate aerial work platforms Check with all Federal State and Local codes and regulations before operation this machine This manual shall be consi...

Page 3: ...WORK PLATFORM 35 TRANSPORTING THE AERIAL WORK PLATFORM ON TO A TRUCK BED 36 4 EQUIPMENT MAINTENANCE 37 BATTERY RECHARGE 38 BATTERY FAULT CODES 39 DAILY SERVICE CHECKS 40 WEEKLY SERVICE CHECKS 43 MONT...

Page 4: ...ULIC OIL 98 9 ANSI REPRINT 105 INSPECTION FORM FOR HAULOTTE AERIAL WORK PLATFORMS 117 LIST OF TABLES TABLE 1 1 MINIMUM SAFE APPROACH DISTANCES 9 TABLE 1 2 BEAUFORT SCALE 12 TABLE 4 1 BATTERY CHARGER F...

Page 5: ...4 10 Level Sensor Digitally Based 48 Figure 4 11 Level Sensor Pendulum Based 48 Figure 4 12 Ground Lower Control Panel for Leveling System 49 Figure 4 13 Platform Position 50 Figure 4 14 Ground Lower...

Page 6: ...OCKETS COMPARTMENT LATCH AXLE CYLINDER LIFT CYLINDER FRONT BOOM REST SECONDARY BOOM CYLINDER SLAVE EXTENSION KNUCKLE PRIMARY PRIMARY BOOM TURNTABLE SECONDRY BOOM PRIMARY BOOM JIB BOOM BOOM REST OUTRIG...

Page 7: ...e use of intelligence and common sense is the best practice when following any safety policy LEGEND SAFETY ADVISORIES The following safety advisories are used throughout this manual to indicate specif...

Page 8: ...m that has any known or suspected defect ALWAYS comply with the instructions found in Safety and or Service Bulletins distributed by the manufacturer factory Bulletins may contain critical procedures...

Page 9: ...n Operate only on surfaces that can support a pressure of 25 psi 1 8 kg cm2 to ensure safe operation ALWAYS keep personnel away from potential pinch and shear points and from potential crush hazards a...

Page 10: ...ing drive operation NEVER allow electrode contact with any part of the aerial work platform while welding from the platform NEVER use the aerial work platform as a ground for welding NEVER operate wit...

Page 11: ...drive functions ALWAYS limit travel speed according to surface conditions slope location of personnel and obstructions and any other factors which may result in collision NEVER operate drive functions...

Page 12: ...motion wind exceeds light flag 8 12 12 19 3 4 5 4 4 Moderate Breeze Raises dust and loose paper small branches are moved 13 17 20 28 5 5 7 9 5 Fresh Breeze Small trees in leaf begin to sway crested wa...

Page 13: ...tions ALWAYS maintain a safe distance while testing the hydraulic components ALWAYS relieve hydraulic pressure before loosening or removing hydraulic components NEVER test or operate the hydraulic com...

Page 14: ...WAYS disconnect ground cable first when removing battery ALWAYS connect ground cable last when installing battery ALWAYS charge batteries in open well ventilated areas ALWAYS replace batteries using o...

Page 15: ...ions Only one telescoping boom motion is permitted at a time and only as long as the telescoping boom is within the safe operating zone When a selected telescoping boom motion exceeds a safe operating...

Page 16: ...ng Radius Inside 11 ft 0 in 3 4 m Outside 16 ft 8 in 5 0 m Platform Dimensions Height 3 ft 7 in 1 1 m Length 2 ft 6 in 0 8 m Width 5 ft 0 in 1 5 m Platform Rotation Type Optional 120 Manual Stowed Dim...

Page 17: ...Secondary Down Slow 74 78 sec Boom Jib Jib Up Fast 8 12 sec Jib Up Slow 12 16 sec Jib Down Fast 20 24 sec Jib Down Slow 38 42 sec Extension Boom Boom Extend Fast 24 28 sec Boom Extend Slow 48 52 sec B...

Page 18: ...ited to engines tires and batteries which may be part of the product are not manufactured or warranted by Haulotte Any applicable warranty for such component is provided through the original manufactu...

Page 19: ...he time the parts order is placed 3 Replacement parts will then be sent by Haulotte Group BilJax to the dealer or distributor All parts are invoiced at dealer distributor list price Credits will be is...

Page 20: ...isual structural damage or when there is suspected internal structural damage Haulotte Group may require that the aerial work platform be returned to our facility for a complete inspection and recerti...

Page 21: ...y diesel The ground lower control panel controls the power outriggers boom lift elevation and rotation functions The platform upper control panel also controls the power outriggers boom lift elevation...

Page 22: ...erations except emergency lowering Removal of the KEY protects against any unauthorized persons attempting to operate the aerial work platform The KEY may be removed with the KEY SWITCH 1 in any selec...

Page 23: ...e will raise the secondary boom Pressing pushing and holding a desired SPEED 15 button and the SECONDARY BOOM DOWN 12 button at the same time will retract the secondary boom Pressing pushing and holdi...

Page 24: ...traction of all four 4 outriggers Select the EXTEND 21 button or RETRACT 22 button and the AUTO LEVEL 23 button at the same time To individually extend or retract the outriggers Select the EXTEND 21 b...

Page 25: ...OW PLUG 2 button for 30 60 seconds then press push the ENGINE START 1 button 3 Engine Stop Press push the ENGINE STOP 3 button to shut the engine OFF 4 Generator On Off To activate and or deactivate t...

Page 26: ...When lit this is an indication of too much weight in the work platform all functional operations become non functional until the weight is below the Maximum Allowable Capacity 500 lb 227kg rating 9C C...

Page 27: ...extend the secondary boom move the JOYSTICK forward to retract the secondary boom 19 Platform Tilt Button Press push the PLATFORM TILT 19 button until the LED is lit Pressing squeezing the ENABLE LEVE...

Page 28: ...hard stop or a safe travel limit Figure 3 3 Platform Controls Joystick Shown upside down and reversed for clarity Boom Rotation Use the TOGGLE SWITCH to determine the direction of rotation To rotate...

Page 29: ...ded Daily Service Checks Refer to the Equipment Maintenance Section of this manual Position the aerial work platform at the work area Make sure the aerial work platform is on a firm and level surface...

Page 30: ...GGER 25 and 26 button and the LED at the AUTO LEVEL 23 button will be lit Refer to Figure 3 5 Figure 3 5 Outrigger Control Panel o Auto Level Press push and hold the EXTEND 21 and AUTO LEVEL 23 button...

Page 31: ...leased the joystick is returned to center or until the boom reaches a hard stop or a safe travel limit NOTE When rotating the turntable press the desired toggle switch the turntable will rotate in the...

Page 32: ...center neutral position Once the work location is reached lower the outriggers and level the aerial work platform using either the ground lower or platform upper control panel Figure 3 6 Drive Speed S...

Page 33: ...proportional valve counterclockwise until it stops and insert pump handle or tire iron into the pump handle fitting Manual Retraction Begin manual retraction or rotation by turning the proportional va...

Page 34: ...the VALVE to lower the platform in case of a complete electrical power failure a load shift or any other emergency The booms may be lowered in any order but the logical order would be The PRIMARY boom...

Page 35: ...se only the designated crane fork lift pockets B Follow all crane operating instructions as indicated by the crane manufacturer When using a forklift use only the designated forklift pockets B Follow...

Page 36: ...ition Secure both BOOM TRAVEL LATCHES A Retract all OUTRIGGER CYLINDERS to the fully stowed upright position Winch tow the boom onto a truck bed or trailer Secure the aerial work platform to the truck...

Page 37: ...Department at 1 800 537 0540 or visit Haulotte Group online at www haulotte usa com if additional information is needed Critical or suspect areas identified during any scheduled inspection of the aer...

Page 38: ...NSION CORD with a maximum length of 50 feet 15 meters to the receptacle located inside the ENGINE COMPARTMENT The generator may need to be disconnected from the receptacle prior to connecting the exte...

Page 39: ...ULT CODES Code Description Limits Cause F0 No Battery 10 volts Loose connection or battery missing F1 Over Voltage 112 charge voltage Connected to wrong battery voltage F2 Over Current 60 amperes Oper...

Page 40: ...located later in this section If the MOTOR CONTROLLER S green light is flashing there is an error refer to the Motor Controller Error Code Definitions TABLE 4 4 ERROR CODE DEFINITIONS MOTOR CONTROLLE...

Page 41: ...ach outrigger Raise all outriggers until the footpads are not in contact with the ground Verify that all outrigger status LEDs on the ground lower control panel are unlit Lower one outrigger until the...

Page 42: ...uge add clean Hydraulic Fluid while all booms are in the stowed down position and the outriggers are fully retracted and in the stowed upright position Pour slowly to avoid creating air pockets in the...

Page 43: ...corrosion Repair all damage remove corrosion and seal with proper materials Inspect the aerial work platform for missing loose or damaged hardware Repair or replace as necessary Inspect all hydraulic...

Page 44: ...ening Sequence Verify that the Level Sensor is operating correctly Fully deploy outriggers until all outrigger LEDs and AUTO LEVEL LED s are lit and the buzzer at the ground lower control panel sounds...

Page 45: ...r annually which ever comes first Run hours are displayed by simultaneous pressing pushing the RABBIT 2 and the TURTLE SPEED 3 buttons on the ground lower control panel and reading the DISPLAY PANEL 1...

Page 46: ...tance between the slew ring gear and the horizontal plate above using a 2 in 50 mm caliper or bore micrometer Refer to Figure 4 7 Figure 4 7 Slew Ring Position Measurement Record the measurement Rotat...

Page 47: ...ork performed and environmental conditions o The inspection and maintenance record of the aerial work platform o The effectiveness of all controls and components o A visual inspection of the aerial wo...

Page 48: ...ions Be aware that the LED s on the top of the sensor will need to be observed the Max Tilt Level Exceeded LED is red and the TILT OK LED is green Press push and hold the SET ZERO button located on th...

Page 49: ...5 buttons and the OUTRIGGER EXTEND 6 button on the ground lower control panel simultaneously and holding for 5 seconds 3 Scroll through the maintenance menu using the TURTLE 7 button to scroll down u...

Page 50: ...er to Figure 4 13 Figure 4 13 Platform Position 2 Use the ground lower control panel to access the control box maintenance menu Refer to Figure 4 14 Figure 4 14 Ground Lower Control Panel for Overload...

Page 51: ...enance mode by pressing pushing both ROTATE 5 buttons and the OUTRIGGER EXTEND 6 button on the ground lower control panel simultaneously and holding for 5 seconds o Scroll through the maintenance menu...

Page 52: ...ratio is not within the above values contact Haulotte Group Customer Service Department at 1 800 537 0540 or visit Haulotte Group online at www haulotte usa com 11 Exit the maintenance mode by scroll...

Page 53: ...rm a test of all functions including brake functions before commissioning or reselling the aerial work platform Always repair or replace all damaged or malfunctioning components before commissioning o...

Page 54: ...this manual if necessary Procedure to raise the outriggers manually Disconnect the outrigger s wire harness from the lower control lower box Refer to Figure 4 16 Plug it into the receptacle on the Ma...

Page 55: ...ic tool when the Boom is NOT performing as expected The female quick disconnect is attached to the Hydraulic Power Unit at the TP1 port Refer to Figure 4 18 The Pressure Gauge is composed of B02 00 00...

Page 56: ...le 3 3 b Refer to error code definitions Table 3 3 Outrigger indicator LED lights do not function a Key switch turned to the OFF or platform controls position b EMERGENCY STOP engaged c Outriggers not...

Page 57: ...wer up This is a latched error Power must be cycled to clear error The Platform Control Engine On LED will also blink a 1 blink error code 006 DRIVE CONTROL HAS STUCK KEY Drive Control has detected a...

Page 58: ...om functions Overload Boom This is a latched error Power must be cycled to clear error Machines with Load Sense option only 020 LOSS OF LOAD CELL CONNECTION Load Sense Module has lost connection with...

Page 59: ...when Extend circuit was energized Use a piece of wire to short the Extend coil This is a latched error Power must be cycled to clear error Checked only at power up 035 OPEN CIRCUIT RETRACT A load of l...

Page 60: ...ched error Power must be cycled to clear error Checked only at power up 050 SHORTED CIRCUIT OUTRIGGER RETRACT Excessive load was detected when Outrigger Retract circuit was energized Use a piece of wi...

Page 61: ...s a latched error Power must be cycled to clear error Not Tested Do not want to crank engine on power up 065 OPEN CIRCUIT ENGINE CHOKE A load of less than 70mA was detected when Engine Choke circuit w...

Page 62: ...error Checked only at power up Machines with Drive option only 081 OPEN CIRCUIT DRIVE ENABLE A load of less than 70mA was detected when Drive Enable circuit was energized Disconnect a wire from Drive...

Page 63: ...up Machines with 4WD option only 095 OPEN CIRCUIT REVERSE 2 C28 A load of less than 70mA was detected when Reverse 2 C28 circuit was energized Disconnect a wire from Reverse 2 C28 coil This is a latch...

Page 64: ...h RPM to a value less than 3000 RPM and attempt to drive This is a latched error Power or engine must be cycled to clear error Machines with 4WS option only 121 OPEN CIRCUIT BRAKE FWS C21 A load of le...

Page 65: ...cled to clear error Checked only at power up Machines with 4WS option only 135 OPEN CIRCUIT DC D FWS C28 A load of less than 70mA was detected when DC D FWS C28 circuit was energized Disconnect a wire...

Page 66: ...ion only 150 SHORTED CIRCUIT FWS R2 Excessive load was detected when FWS R2 circuit was energized Use a piece of wire to short the FWS R2 coil This is a latched error Power must be cycled to clear err...

Page 67: ...y at power up Machines with 4WS option only 163 OPEN CIRCUIT FWS PROP A2 A load of less than 70mA was detected when FWS Prop A2 circuit was energized Disconnect a wire from FWS Prop A2 coil This is a...

Page 68: ...normally None required 1 11 Configuration Range Error One or more controller personality settings are out of range Use Sevcon calibrator to enter correct settings from latest Personality Sheet 1 12 CR...

Page 69: ...l If fault repeatedly occurs look for binding on the hydraulic cylinders or sticking valves Otherwise the pump motor may be failing 8 3 Pump I 2 T Current Limit Cutback Maximum power available to pump...

Page 70: ...HAULOTTE GROUP 5 CYLINDER REPLACEMENT 70...

Page 71: ...e at www haulotte usa com MASTER SLAVE CYLINDER REPLACEMENT Use the following procedure to remove and replace faulty cylinders Master Cylinder Refer to Figure 5 1 for the location of this cylinder Wit...

Page 72: ...nd the telescoping boom until there is adequate exposure of the pin retainer and pivot pin approximately 2 ft 0 7 m Verify that the upper boom is supported by lifting straps and an overhead hoist or e...

Page 73: ...for the location of these cylinders Figure 5 3 Location of Manual Lowering Valves for Lift Cylinder Replacement With the boom in the stowed position press push in and hold the emergency lowering valve...

Page 74: ...e numbers Place absorbent cloths below the cylinder ports and detach hydraulic hoses from the cylinder Elevate hoses to prevent leakage Plug or cap exposed hose fittings and cylinder ports At the base...

Page 75: ...ylinder unbolt and remove the pin retainer from each side of the pivot pin Place a block of wood shoring between the outrigger tube and the cylinder Remove the pivot pin using a hammer and a brass or...

Page 76: ...using an overhead hoist and lifting straps or equivalent Replace or reinstall the cylinder by following the above instructions in the reverse order of removal Actuate the hydraulic system and check f...

Page 77: ...ion that is required for the safe and proper use of the aerial work platform Decals should be considered necessary components of the machine and should be checked before each use to verify that they a...

Page 78: ...HAULOTTE GROUP 6 DECAL REPLACEMENT 78 DECAL KIT ANSI...

Page 79: ...Notice Lanyard Attachment 1 17 B06 00 0471 Decal Danger Main Instruction Hazard Platform 1 18 B06 00 0062 Decal Notice AC Power 2 19 B06 00 0473 Decal Notice Operator Manual Missing 1 20 B06 00 0475...

Page 80: ...HAULOTTE GROUP 6 DECAL REPLACEMENT 80 IDENTIFICATION PLATES OPTIONAL EQUIPMENT ANSI...

Page 81: ...06 00 0526 Key Ring Tag 1 38 B06 00 0524 Annual Inspection Plate 1 39 B06 00 0639 ANSI ID Plate 1 REPLACEMENT DECALS FOR OPTIONAL EQUIPMENT ANSI ITEM NO PART NUMBER DESCRIPTION QTY 40 B06 00 0529 Deca...

Page 82: ...HAULOTTE GROUP 6 DECAL REPLACEMENT 82 DECALS ANSI 0202 0523 B06 00 0161B B06 00 0530 B06 00 0531 B06 00 0484 B06 00 0034 B06 00 0482 B06 00 0521 B06 00 0564 B06 00 0471 B06 00 0536 45XA HLA 16 PX...

Page 83: ...HAULOTTE GROUP 6 DECAL REPLACEMENT 83 DECALS ANSI CONTINUED B06 00 0037 B06 00 0404 B06 00 0475 B06 00 0405 B06 00 0481 B06 00 0477 B06 00 0561 B06 00 0505...

Page 84: ...HAULOTTE GROUP 6 DECAL REPLACEMENT 84 DECALS ANSI CONTINUED B06 00 0552 B06 00 0495 B06 00 0504 B06 00 0488 B06 00 0562 B06 00 0544 B06 00 0581 B06 00 0608 B06 00 0541 B06 00 0639...

Page 85: ...ULOTTE GROUP 6 DECAL REPLACEMENT 85 DECALS ANSI CONTINUED B06 00 0487 B06 00 0485 B06 00 0062 B06 00 0497 B06 00 00068 B06 00 0403 B06 00 0473 B06 00 0529 B06 00 0494 B06 00 0498 B06 00 0503 B06 00 04...

Page 86: ...HAULOTTE GROUP 6 DECAL REPLACEMENT 86...

Page 87: ...or modifications or otherwise alter the equipment in any way that is not expressly recommended by the manufacturer When operating an aerial work platform equipped with optional components observe all...

Page 88: ...rd from the cord wrap on the platform Disconnect the platform upper control box s PLUG from the LOAD SENSE MODULE located on the PLATFORM MOUNT Refer to Figure 7 1 Figure 7 1 Disconnect Plug from Load...

Page 89: ...E located on the PLATFORM MOUNT NOTE If the loopback plug is not inserted into the Load Sense the Emergency Stop circuit will not be complete and the aerial work platform will not function Firmly secu...

Page 90: ...l WARNING ALWAYS observe the manufacturer s weight lifting limitations when using the material lifting hook ALWAYS use lifting straps or wire rope slings that are rated at a minimum 500 lb 227kg lifti...

Page 91: ...ator turn the rotator handle in the direction of desired rotation clockwise or counterclockwise Motion continues in the desired direction until rotator handle is released or the platform reaches a saf...

Page 92: ...HAULOTTE GROUP 7 OPTIONAL EQUIPMENT 92...

Page 93: ...16 PX Self Propelled Aerial Work Platform as well as any potential health and safety hazards related to these chemicals Material Safety Data Sheets are included here in accordance with applicable fede...

Page 94: ...HAULOTTE GROUP 8 MATERIAL SAFETY 94 MATERIAL SAFETY DATA SHEET LEAD ACID BATTERIES WET FILLED WITH ACID UN 2794 CONT...

Page 95: ...HAULOTTE GROUP 8 MATERIAL SAFETY 95 MATERIAL SAFETY DATA SHEET LEAD ACID BATTERIES WET FILLED WITH ACID UN 2794 CONT...

Page 96: ...HAULOTTE GROUP 8 MATERIAL SAFETY 96 MATERIAL SAFETY DATA SHEET LEAD ACID BATTERIES WET FILLED WITH ACID UN 2794 CONT...

Page 97: ...HAULOTTE GROUP 8 MATERIAL SAFETY 97 MATERIAL SAFETY DATA SHEET LEAD ACID BATTERIES WET FILLED WITH ACID UN 2794 CONT...

Page 98: ...HAULOTTE GROUP 8 MATERIAL SAFETY 98 MATERIAL SAFETY DATA SHEET POWERFLOW AW HVI HYDRAULIC OIL...

Page 99: ...HAULOTTE GROUP 8 MATERIAL SAFETY 99 MATERIAL SAFETY DATA SHEET POWERFLOW AW HVI HYDRAULIC OIL CONTINUED...

Page 100: ...HAULOTTE GROUP 8 MATERIAL SAFETY 100 MATERIAL SAFETY DATA SHEET POWERFLOW AW HVI HYDRAULIC OIL CONTINUED...

Page 101: ...HAULOTTE GROUP 8 MATERIAL SAFETY 101 MATERIAL SAFETY DATA SHEET POWERFLOW AW HVI HYDRAULIC OIL CONTINUED...

Page 102: ...HAULOTTE GROUP 8 MATERIAL SAFETY 102 MATERIAL SAFETY DATA SHEET POWERFLOW AW HVI HYDRAULIC OIL CONTINUED...

Page 103: ...HAULOTTE GROUP 8 MATERIAL SAFETY 103 MATERIAL SAFETY DATA SHEET POWERFLOW AW HVI HYDRAULIC OIL CONTINUED...

Page 104: ...HAULOTTE GROUP 8 MATERIAL SAFETY 104 MATERIAL SAFETY DATA SHEET POWERFLOW AW HVI HYDRAULIC OIL CONTINUED...

Page 105: ...n aerial platform the following precautions shall be taken as applicable 1 Power plant stopped and starting means rendered inoperative 2 All controls in the Off position and all operating systems secu...

Page 106: ...that the aerial platform will be carrying personnel 6 2 Responsibilities Upon Purchase Upon purchase of the aerial platform the buyer 1 Shall ensure the operating and maintenance manuals have been rec...

Page 107: ...an owner directs or authorizes an employee to operate an aerial platform loading unloading inspecting or any form of use the owner shall assume the responsibilities of the user as specified in Section...

Page 108: ...e weather resistant storage compartment 7 3 Inspection and Maintenance Users shall inspect and maintain the aerial platform as required to ensure proper operation The frequency of inspection and maint...

Page 109: ...protect against the potential effects of ejection or a fall restraint system to prevent free fall a Election of Systems The user may elect to use either a restraint or an arrest system 1 Fall Restrai...

Page 110: ...evated the user shall direct the operator to a Maintain a clear view of the support surface and route of travel b Ensure personnel in the worksite area that may be affected are aware of the movement c...

Page 111: ...ated bulletins as received from the manufacturer dealer or owner 8 Responsibilities of Operators 8 1 Basic Principles The information in this standard shall be supplemented by good judgment safety con...

Page 112: ...operator shall direct personnel operating the aerial platform to be in compliance with the provisions set forth in this standard The operator shall monitor their performance and supervise their work...

Page 113: ...The operator shall implement means provided to protect against use by an unauthorized person s 26 Altering safety devices Interlocks or other safety devices shall not be altered or disabled 27 Snagge...

Page 114: ...he aerial platform will be carrying personnel 10 2 Lessee as a Dealer When a lessee uses the aerial platform as a dealer the lessee shall have the responsibilities of dealers as specified in Section 5...

Page 115: ...00KV to 750KV 35 10 67 Over 750KV to 1000KV 45 13 72 DANGER DO NOT allow aerial work platform personnel or conductive materials inside prohibited zone Maintain M S A D from all energized lines and par...

Page 116: ...HAULOTTE GROUP 9 ANSI REPRINT 116...

Page 117: ...D Inspect hydraulic system and fluid levels D Check battery electrolyte level W Inspect electrical wiring for damaged broken or frayed wires W Inspect transport hitch for damage Applicable for machine...

Page 118: ...Distributed by 125 Taylor Parkway Archbold Ohio 43502 Phone 800 537 0540 419 445 8915 Fax 419 445 0367 www haulotte usa com B33 01 0104 Rev 4 45XA HLA 16 PX Operator s Maintenance Manual August 2012...